Aber FUTURA neo User manual
© Aber® Instruments Ltd 2021.
Under the copyright laws, this manual may not be copied, in whole or in part in any form or by any means,
whether mechanical or electronic, without the written consent of Aber Instruments Ltd. All rights reserved under
International and Pan-American Copyright Conventions
Every effort has been made to ensure that the information in this manual is accurate. Aber Instruments Ltd is not
responsible for printing or clerical errors. As research and development is a continual process, Aber Instruments
Ltd. reserves the right to change the features and specifications described herein without notice or obligation.
Other product names mentioned herein are trademarks of their respective companies. Mention of third party
products is for informational purposes only and constitutes neither an endorsement nor a recommendation.
Aber Instruments Ltd
Science Park
Aberystwyth
Ceredigion
UK
SY23 3AH
+44 (0) 1970 636300
www.aberinstruments.com
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Table of Contents
1 Product Safety and EMC Regulatory Information 7
1.1.1 Disclaimer 7
1.1.2 Electromagnetic Compatibility 7
European Region 7
Great Britain 8
North America Region 8
1.1.3 Generic product label identification 9
Symbol 9
Meaning 9
1.2 FUTURA Connect 1, FUTURA Connect 4 and FUTURA Connect Xtra 10
1.2.1 Safety Statement 10
2 Introduction 11
2.1 About This Manual 11
2.2 Concepts 12
2.3 System Components Overview 13
2.3.1 Probe 14
2.3.2 FUTURA 14
2.3.3 FUTURA Connect 14
FUTURA Connect 14
FUTURA Connect Xtra 15
2.3.4 Software 16
FuturaTool 16
FUTURA SCADA 16
2.4 Summary 17
3 Quick Setup Guide 18
3.1 Typical System Checklist 18
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3.2 Getting Started 19
3.2.1 Unpacking 19
3.2.2 Software Installation 19
3.2.3 Connecting Probes and Cables 19
FUTURA Connectors 19
Power → FUTURA Connect 20
Probe → FUTURA → FUTURA Connect 20
3.2.4 Connecting FUTURA to a PC 20
4 System Check 21
4.1 Using Signal Simulators 21
Directions 21
5 FUTURA System Components 22
5.1 FUTURA neo Head Amplifier 22
5.1.1 FUTURA neo Aftercare 23
How to Store Your FUTURA neo 23
How to Clean Your FUTURA neo 23
5.1.2 Firmware Upgrades 24
Prerequisites 24
Firmware Upgrade Instructions 24
5.1.3 Earthing the FUTURA 26
5.2 FUTURA neo Probes 27
Connection 27
5.2.1 Probe Calibration 28
5.3 FUTURA Connect 29
5.3.1 Power Supply 30
5.3.2 Connections 31
Power Connector 33
FUTURA Connections 33
FUTURA Status Indicators and Zero buttons 33
USB Connector 34
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Current Loop Connections 34
Modbus Connection 35
5.3.3 Pinouts for Current Loops 36
FUTURA Connect 1 36
FUTURA Connect 4 37
5.3.4 Pinouts for Modbus 38
FUTURA Connect 1 38
FUTURA Connect 4 38
5.3.5 FUTURA Connect Aftercare 39
How to Store Your FUTURA Connect 39
How to Clean Your FUTURA Connect 39
5.4 Aber Cables 40
5.4.1 Cable Types 41
FUTURA Extension Cable (FHAX) 41
FUTURA Bulkhead Cable (FHABX) 41
6 Measurement Options 42
6.1 Measurement Modes - Description 42
6.1.1 Measurement Modes Available 42
Cell Culture Mode 42
Bacterial Mode 42
Microbial Mode 43
Custom Mode 43
Signal Simulator Mode 43
6.1.2 Selecting a Measurement Mode 44
FuturaTool 44
Modbus 45
6.2 Zeroing 46
6.2.1 Zeroing Using FuturaTool 46
6.2.2 Zeroing Using Modbus 46
6.2.3 Zeroing Using FUTURA Connect 46
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6.2.4 Polarisation Correction 47
6.3 Filters 47
6.4 Calibrating the Biomass Reading to the units you want 48
7 Using Current Loops 49
7.1 Current Loops using a FUTURA Connect 50
8 Using Modbus RTU 51
8.1 FUTURA Modbus Memory Map 52
9 Troubleshooting 59
9.1 Noisy or Unexpected Readings 59
9.2 Noisy Capacitance Readings 59
9.3 Lid Lock Warning (E10 Error) 59
9.4 FUTURA Busy (E02 Error) 60
9.5 FUTURA Connect Failing to Zero FUTURA 60
9.6 FUTURA Not Recognised by Computer 60
10 Technical Specifications 61
10.1 FUTURA neo Probe 61
10.1.1 Probe Environmental and Operational Specifications 61
10.2 FUTURA neo Head Amplifier 62
10.3 FUTURA Connect 63
10.3.1 FUTURA Connect Specifications 63
10.3.2 FUTURA Connect Xtra Specifications 64
11 Detailed Theory of Operation 65
11.1 The Electrical Properties of Living Systems 65
11.2 Beta Dispersion 66
11.3 Conductivity 69
12 Limited Warranty and Disclaimer 70
THIS WARRANTY DOES NOT APPLY IN THE FOLLOWING CIRCUMSTANCES: 70
12.1 Limited Liability Statement 71
LIMITATION OF LIABILITY 71
CONTACT INFORMATION 71
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13 Software Licences 72
ABER INSTRUMENTS SOFTWARE LICENCE AGREEMENT 72
13.1.1 Definitions 72
13.1.2 Grant of License 72
13.1.3 Registration 73
13.1.4 Support 73
13.1.5 Restrictions 73
13.1.6 Warranty 73
13.1.7 Copyright 73
13.1.8 Patent and Trademark Notice 73
13.1.9 Distribution Requirements 74
13.1.10 Warning 74
13.1.11 Termination 74
13.1.12 General 74
13.1.13 Open Source Software 75
14 Document Revision History 76
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1 Product Safety and EMC Regulatory Information
1.1.1 Disclaimer
The manufacturer discourages the removal of any panel or lid on these instruments. There are no user-serviceable
parts inside and opening the case could disturb calibration.
Furthermore, removal of any panel or lid will invalidate the integrity of the manufacturer’s rigorous Electrical
Safety Tests. Aber Instruments Ltd recommends a return to base policy for any upgrades or repairs that cannot
be carried out by authorised field service engineers.
If removal of any instrument panel is deemed necessary, please contact Aber Instruments Ltd. Such procedures
should only be carried out by suitably qualified personnel who will take responsibility for the future Electrical
Safety integrity of the instrument.
The system must be powered down during any maintenance work.
Radioactive accessories are not permitted to be used with Aber products.
1.1.2 Electromagnetic Compatibility
European Region
This product has been tested and complies with EU Directives 2014/35/EU (Low Voltage), 2014/30/EU
(Electromagnetic Compatibility), and 2011/65/EU (RoHS as amended by EU 2015/863).
For a list of standards, refer to our EU DoC that can be found by contacting Aber Instruments on
+44(0)1970636300 or emailing support at [email protected] .
It meets Class A, Group 1 Limits as described in EN 61326-1 (and CISPR 11/EN 55011:2009). Class A equipment is
equipment suitable for use in all establishments other than domestic and those directly connected to a low
voltage power supply network which supplies buildings used for domestic purposes.
Warning : in a domestic environment this product may cause radio interference in which case the user may be
required to take adequate measures.
It also complies with the essential EEA requirements for Electrical Safety as set out in the Low Voltage Directive
2014/35/EU. It has been assessed and found to comply with the requirements of:
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EN 61010:2010
Safety requirements for electrical equipment for measurement, control and laboratory use.
Great Britain
This product also complies with the following Statutory Instruments.
For a list of standards, refer to our UK DoC or contact Aber on the above for EU DoC.
*As amended by EU Exit Regulations.
North America Region
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his own expense.
These devices comply with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
The probe sensing electrodes are the most vulnerable part of the equipment to static discharge damage. Because
of this (and to avoid contamination) it is good practice not to touch the sensing electrodes.
The FUTURA System incorporates protection from mains-borne fast transient interference and from
Radio-Frequency field interference. However, because the equipment works by detecting very small
radio-frequency signals at the probe it is possible that high levels of RF energy coupled into the probe electrodes
could disturb the readings. Typically this disturbance is very low for field strengths of up to about 3 Volt/metre.
Most radio signal strengths are only millivolts/metre. A 5 Watt mobile radio transmitter would still typically be
below the 1 V/m, (±2 pF/cm worst case disturbance) at a distance of only 4 metres. However, the use of a mobile
radio very close to the equipment could cause much higher fields and could, if the frequency happened to coincide
with one of the instrument’s critical frequencies, result in larger temporary disturbances to the readings. The
readings will recover without operator intervention when the high field is removed. In practice this has not been a
problem.
To minimise the chances of interference affecting the instrument, the installation and connection instructions
outlined in later sections of this manual should be adhered to. It is also good practice to route FUTURA system
cables away from power cables carrying high transient currents, such as those feeding variable speed motor
drives.
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SI 2016 No. 1101
The Electrical Equipment (Safety) Regulations 2016*
SI 2016 No. 1091
The Electromagnetic Compatibility Regulations 2016*
SI 2012 No. 3032
The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic
Equipment Regulations 2012*
1.1.3 Generic product label identification
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Symbol
Meaning
This product complies with the essential EEA requirements for the
Electromagnetic Compatibility (EMC) Directive 2014/30/EU, the Low Voltage
Directive (LVD) 2014/35/EU and the Restriction of the use of certain
Hazardous Substances Directive (RoHS) 2011/65/EU
Contains hazardous components and must not be disposed of at a
household waste site. Instead it should be taken to the appropriate
collection point for the recycling of electrical and electronic equipment.
Power supply ratings are 24 V DC at 2.5 A.
Negative is connected to the outer contact and centre pin is connected to
the positive supply on this terminal.
Use only Aber Instruments supplied Power Supply Unit SPU61A-108-ABER
with this product.
USB
Refer to User Manual
Keep dry and away from moisture
Indoor use only
Caution, risk of electric shock
Caution, risk of danger
Ground symbol (SBM220)
1.2 FUTURA Connect 1, FUTURA Connect 4 and FUTURA Connect Xtra
1.2.1 Safety Statement
Please read this manual fully and carefully before starting to use the instrument.
This symbol on the front or rear of the FUTURA Connect warns the user to consult the appropriate parts of the
User Manual before making any connections. Wrong connections, voltages or currents outside the specified
operating ranges could cause danger or permanent damage to the equipment.
This equipment is designed to meet the requirements of the international standard EN61010-1 “Safety
Requirements for Electrical Equipment for Measurement, Control and Laboratory Use” (2001), and is suitable for
environments of Pollution Degree 2 and Installation Category II. The FUTURA System is suitable for laboratory or
similar use by skilled/trained persons. The FUTURA Connect Power Supply Unit is not designed to be used in wet
or otherwise more hostile environments, unless it is installed in a suitable environmental enclosure. Contact Aber
Instruments for advice. The instrument must never be used in explosive atmospheres.
The FUTURA Connect Power Supply Unit can be operated from an AC supply of 50/60 Hz, 100 to 240 volts nominal,
without adjustment. A 3-core mains input lead is provided.
The mains supply should be from a standard 3-pin electrical outlet having a voltage within the range stated in the
preceding paragraph. The supply should have a fuse or overcurrent trip rated between 4 and 10 Amps.
The FUTURA System is CLASS I equipment and MUST BE EARTHED. The earth conductor in the mains cable
supplied is adequate for this purpose, provided that the instrument is plugged in to an electrical supply socket
that has a suitable earth connection.
It is the responsibility of the customer to ensure that the unit is correctly connected to a mains supply in
accordance with current safety standards of the country in which the instrument is being used.
CAUTION: There are no user serviceable parts inside.
Ensure that the FUTURA System components have adequate space for ventilation. It will operate safely in
ambient temperatures up to 40 °C.
Do not use or continue to use the equipment if it shows any signs of being defective, overheating, or if it has
been modified by anyone other than Aber Instruments Ltd. Do not operate the equipment with any part of its
enclosure removed. The equipment must not be used for anything other than the intended purpose.
The instrument may be cleaned with a damp cloth and mild detergent. Disconnect from the mains supply before
cleaning.
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2 Introduction
Thank you for purchasing an Aber® FUTURA® neo Biomass Monitoring System.
Aber has been pioneering the development and use of dielectric instrumentation for the measurement of cell
capacitance and media conductivity since 1988. Over the years, Aber has been the proven world leader in
supplying biomass monitors to the Biotech industry. The FUTURA, which is our third generation of biomass
monitor, takes advantage of miniaturisation of electronics to help us provide a product that better meets the
needs of the industry. The fourth generation sees the arrival of the FUTURA neo, which benefits from a further
size reduction. The introduction of digital technology also provides improved signal-to-noise ratio and reduced
temperature drift. For clarity, references to the FUTURA also include the FUTURA neo unless otherwise stated. The
same convention applies to the FUTURA probe and Connect module (includes Connect Xtra).
2.1 About This Manual
The aim of this manual is to provide both a practical guide to setting up your FUTURA neo system and a
comprehensive reference for each element of the FUTURA neo system.
If you are familiar with our technology and general software installation, we recommend that you read the rest of
this introductory section, the Quick Setup Guide ( Chapter 3 ) and System Check ( Chapter 4 ) as a minimum,
referring to later chapters where necessary. Other chapters include more detailed descriptions of the individual
components in your FUTURA system and the various measurement options available to you. Comprehensive
guides for setting up your FUTURA as a standalone system or as part of a larger control or measurement system
are also included. Technical Specifications, Software Licence Agreements and EMC Regulatory Information
sections can all be found towards the beginning of this manual.
Please read this manual fully and carefully before starting to use this equipment. Failure to comply with the
appropriate safety guidelines may cause severe injury or property damage.
This symbol on Aber Instruments’ equipment warns the user to consult the appropriate parts of the User Manual
before making any connections. Wrong connections, voltages or currents outside the specified operating ranges
could cause danger or permanent damage to the equipment.
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2.2 Concepts
The FUTURA System measures an electrical property of cell suspensions called Capacitance. Academic and
industrial research has demonstrated a correlation between this property and live biomass. A detailed theory of
operation can be found in Chapter 11 .
Electrical capacitance is measured in the SI unit farads (F), although picofarads (pF) are more common in practical
use. For cell suspensions capacitance is usually quoted in pF/cm and as a rule of thumb, one pF/cm equates to
one gram per litre of dry weight for microbial or 1 x 10
6
cells per millilitre of live cells for cell culture.
Aber’s patented technology converts capacitance into a live biomass reading, typically cells/ml or g/l for Spun
Solids dry weight. However, other units can be derived from the raw capacitance measurements; these may be
more relevant to the chosen application and are covered later in the manual.
Your FUTURA also measures the Conductivity of the medium, in millisiemens per centimetre (mS/cm). Conductivity
is not used to measure biomass but is indicative of the production or utilisation of ions by the cell suspension, e.g.
pH control and other fermentation processes.
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2.3.1 Probe
The probe is the part of the instrument that is installed in the single use bioreactor to measure the solution. It
can be physically separated from the rest of the system for replacement.
Aber has a range of re-usable and single use probes and electronics in a range of different shapes and sizes to
suit different applications. Please contact Aber sales for more information.
The neo probes are warranted for single use, the Warranty Period will not in any case exceed the expiration date
on the Product label or 2 years after the point of sterilisation.
2.3.2 FUTURA
The FUTURA is the main processing engine in the FUTURA system, called the Head Amplifier in older Aber biomass
systems. In order to limit the physical dimensions, the Head Amplifier traditionally contained only a small part of
the overall circuitry needed, requiring connection to a much larger desktop/wall mount unit which housed the
main processing engine. Due to major advances in electronic miniaturisation, the FUTURA now contains the entire
analogue and digital processing requirements which make it an extremely compact, yet powerful, standalone
instrument.
2.3.3 FUTURA Connect
The FUTURA Connect comes in two main types: the original Connect module and the Connect Xtra.
FUTURA Connect
Three variants exist that enable connection of between one and four FUTURA-probe combinations. For each
connected FUTURA the FUTURA Connect can simultaneously output Current Loop and Modbus RTU signals for use
with PLCs and other control systems whilst optionally interfacing with a PC over a single USB cable, allowing
independent control, calibration, monitoring and logging of all FUTURAs connected to the system using Aber
software.
Modbus and Current Loop signals from the FUTURA Connect provide third party control systems (e.g. PLCs) with
both capacitance and conductivity readings for evaluation in control functions. Once configured using Aber
software the FUTURA Connect modules can be operated indefinitely without needing to be connected to a PC.
In addition to capacitance and conductivity readings, Modbus also has the facility to provide a viable biomass
reading and offers control and configuration over both FUTURA and probe.
The diagram on the following page shows the typical connection layout of a small biomass monitoring system
using a Connect 4.
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FUTURA Connect Xtra
The Connect Xtra enables OPC communications via a plug-in module. The plug-in module is interchangeable to
provide network flexibility. A single FUTURA channel is supported. The plug-in module supersedes the direct
Modbus interface and current loop connections.
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2.3.4 Software
You should have received a USB flash drive with your FUTURA system. This contains a copy of FuturaTool (for
system configuration) and FUTURA SCADA (if purchased; for data logging and real time measurements). If this is
missing from your package, please contact Aber or your authorised distributor for assistance.
FuturaTool
FuturaTool is required to configure your FUTURA system for use. It provides details on the FUTURA and probes
attached to the system, calibration and operating mode options, a quick readings mode for ascertaining operating
status and other advanced functions.
For further details on FuturaTool, including system requirements and installation instructions, please refer to the
FuturaTool User Manual (Aber part number 2860-09).
FUTURA SCADA
FUTURA SCADA is a GAMP 5 compliant software package that allows the end user on one screen to:
●Set up and then optimise each individual FUTURA system.
●Provide continuous data collection for any number of FUTURA systems with an events timeline.
●Provide frequency scanning to calculate some additional parameters (including Delta C, critical frequency
and Cole-Cole alpha) and derive information on the cells (including cell bio-volume and diameter).
●Carry out retrospective analysis of separate data sets from different experiments. Data is easily exported
to Microsoft Excel via simple .csv files.
●Monitor probe life parameters.
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Advantages of using FUTURA SCADA:
●The software systems no longer have to be restricted to banks of four channels. This saves you time as
all the information for hundreds of FUTURAs is on one screen in your control room.
●FUTURA SCADA has no tag licence fee and brings all your biomass related data and alarms into the
control room at minimum cost.
●The software is modular so you can add functionality by upgrading and simply entering licence keys.
●Different vessel types and labels can be chosen to enhance the user interface. FUTURA SCADA also has
intuitive presets and offers facilities for use of custom calibrated probes with a simple wizard based
system.
Please contact Aber or your authorised distributor for more information.
2.4 Summary
●Aber FUTURA is a complete instrument; it has all the biomass monitoring processing power of other
monitors contained within a small lightweight housing.
●It can be directly mounted onto the probe or connected via a small preamplifier.
●Bus connectivity of the FUTURA removes the need for an additional multiplexer.
●Multiple FUTURA systems can be easily incorporated into most modern bioreactor controllers and SCADA
systems.
●The advanced frequency scanning capability provides biomass spectra and additional critical process
parameters, including bio-volume and cell size.
●Data security is provided through improved measurement accuracy and information on the probe.
●Full audit trail is provided by tracking changes in the integral memory.
●Full IOQ documentation makes it the ideal choice for cGMP.
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3 Quick Setup Guide
This section assumes the user is familiar with Aber technology and also the installation of software within the
Microsoft windows framework. Details on the workings of Aber technology and the installation of software are
expanded upon in the following chapters.
FUTURA systems will vary but the essential elements are very similar. The following is a description of a typical
system and allows the user to unpack, recognise each element, install the software onto a PC, connect it together
and check that it functions properly.
3.1 Typical System Checklist
A FUTURA system will typically consist of the following:
●FUTURA neo Probe (pre-installed in your SUB)
●FUTURA neo Head Amp
●FUTURA Connect (1- or 4-way)
●Mains power cable for FUTURA Connect (this should be correct for your country/region)*
●Two Signal Simulators (0pF/cm, 0mS/cm and 100pF/cm, 40mS/cm)*
●Set of green phoenix connectors for Current Loop and Modbus connections (FUTURA Connect only)*
●USB cable*
●USB flash drive containing FuturaTool software*
●FUTURA System Manual (this document)*
*Not shown
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FUTURA Connect 4
FUTURA neo
neo Probe
3.2 Getting Started
3.2.1 Unpacking
It is recommended that you unpack all the items and lay them out in a clear space.
Check all items for signs of damage. If you suspect an item to be damaged, or if anything appears to be missing,
contact the shipper and Aber or your local distributor within three days of receipt of the shipment.
The packaging in which the items were dispatched is specially designed to protect them during transport. We
recommend that the packaging be retained for use in the unlikely event that any item needs to be returned to
Aber.
3.2.2 Software Installation
Do not connect the FUTURA to a PC until all required software has been installed. Please refer to the FuturaTool
User Manual (Aber part number 2860-09) for installation instructions.
3.2.3 Connecting Probes and Cables
FUTURA Connectors
It is easy to connect FUTURA cables to FUTURA Connect units. Simply line up the coloured dot on the connector
with the coloured dot on the socket and push in. However, the connectors feature a special ring lock device that
will not allow them to be removed unless the correct technique is used, as described below.
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The plug collar indicated must be pulled out a short
distance (the distance is almost imperceptible; less
than 1 mm) from the socket to disengage the lock.
Continue to pull on the plug collar to uncouple the
plug from the socket.
For a cable, hold the collar as shown and pull away
from the socket. For a reusable probe, the process is
the same but please note that the collar is attached
to the probe. When the probe is connected to a
vessel, be sure to pull the plug collar away from the
FUTURA (towards the probe) and lift the FUTURA away
from the probe-vessel assembly.
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